Method and device for reducing heavy polycyclic aromatic compounds in hydrocracking units

ABSTRACT

The invention concerns a process and a facility for reducing the concentration of heavy polycyclic aromatic compounds (HPNA) in the recycle loop of hydrocracking units, which comprises a fractionation column. 
     In accordance with this process, a portion of the stream present at the level of at least one plate located between the plate for supplying hydrocracked effluent and the plate for withdrawing the distillate fraction which is the heaviest is withdrawn from the fractionation column and at least a portion of said withdrawn stream is recycled to the column directly or after optional liquid separation, and optionally a portion of said withdrawn stream is recycled to the hydrocracking step directly or after optional gas separation.

The invention relates to a process and a device for reducing the concentration of heavy polycyclic aromatic compounds (HPNA) in the recycle loop of hydrocracking units.

Hydrocracking processes are routinely used in refining to transform mixtures of hydrocarbons into products which can be upgraded easily. These processes may be used to transform light cuts such as gasolines, for example, into lighter cuts (LPG). However, they are more usually used to convert heavier feeds (such as oil cuts or heavy synthetics, for example gas oils obtained from vacuum distillation or effluents from a Fischer-Tropsch unit) into gasoline or naphtha, kerosene or gas oil. This type of process is also used to produce oils.

In order to increase the conversion of hydrocracking units, a portion of the unconverted feed is recycled, either to the reaction section through which it has already passed, or to an independent reaction section. This causes an unwanted accumulation in the recycle loop of polycyclic aromatic compounds formed in the reaction section during cracking reactions. These compounds poison the hydrocracking catalyst, which reduces the catalytic activity as well as the cycle time. They can also precipitate or be deposited in the cold parts of the unit, thus generating disruptions.

Thus, there is a need for improving the hydrocracking process in order to reduce the formation of polycyclic aromatic compounds or to eliminate them without reducing the yield of upgradeable products.

HPNA compounds are defined as polycyclic or polynuclear aromatic compounds which thus comprise several condensed benzene nuclei or rings. They are usually known as HPA, Heavy Polynuclear Aromatics, or PNA or HPNA.

Typically, HPNAs known as heavies comprise at least 4 or even at least 6 benzene rings in each molecule. The compounds with fewer than 6 rings (pyrene derivatives, for example) can be hydrogenated more easily and are thus less likely to poison the catalysts. As a consequence, we are more particularly interested in compounds that are the most representative of families containing 6 aromatic rings or more such as, for example, coronene (a compound containing 24 carbon atoms), dibenzo(e,ghi) perylene (26 carbon atoms), naphtho[8,2,1,abc] coronene (30 carbon atoms) and ovalene (32 carbon atoms), which are the compounds which are the most easily identifiable and quantifiable, for example by chromatography.

The Applicant's U.S. Pat. No. 7,588,678 describes a hydrocracking process with a recycle of the unconverted 380° C.+ fraction, in which process the HPNA compounds are eliminated from the recycled fraction by means of an adsorbent. Other techniques for reducing the quantity or for eliminating the HPNA are described in the prior art for that patent such as, for example, their reduction via a hydrogenation or their precipitation followed by a filtration.

The U.S. Pat. No. 4,961,839 describes a hydrocracking process for increasing the conversion per pass using high flow rates of hydrogen in the reaction zone, by vaporizing a large proportion of the hydrocarbons sent to the column for separating the products and by concentrating the polycyclic aromatic compounds in a small heavy fraction which is extracted from that column. In that process, a heavy fraction is withdrawn from the level of a plate located above the supply point and below the point for withdrawing the gas oil distillate; that heavy fraction is recycled to the hydrocracker. The bottom of the column (residue) is recycled directly to the fractionation column. That type of technique can indeed reduce the concentration of HPNA in the recycle loop to the reactor, but results in significant losses of yields and high costs linked to the quantities of hydrogen.

The patent applications WO 2012/052042 and WO 2012/052116 (corresponding to US-2013/0220885) describe a hydrocracking process in which the bottom of the fractionation column (residue) is stripped as a counter-current in a stripping column. The light fraction obtained after stripping is sent to the fractionation column and at least a portion of the heavy fraction obtained from stripping is purged, the other portion of that fraction optionally being recycled to the stripping column.

Those processes have brought about improvements in the reduction of HPNAs, but often to the detriment of the yields and costs.

The process of the invention can not only be used to concentrate the polycyclic aromatic hydrocarbons in the unconverted fractions (residues) in order to eliminate them and reduce the quantity of residue purged in order to increase the conversion, but also be used to improve the yield of upgradeable products (for example by preventing over-cracking of gas oil) and/or the catalytic cycle time compared with prior art processes. The invention also has the advantage of considerably reducing the quantity of HPNA containing at least 6 aromatic rings presented to the hydrocracker and which are the most refractory to the reactions occurring during hydrocracking.

The process in accordance with the invention is based on positioning a side stream above the supply to the column, and below the withdrawal for the heaviest gas oil distillate, returning all or a portion of said withdrawn fraction to the column, optionally separated from the liquid. This results in super-evaporation. The liquid is preferably separated by combining a stripper with the fractionation column, which strips said withdrawn fraction.

More precisely, the invention concerns a process for hydrocracking an oil feed comprising at least 10% by volume of compounds boiling above 340° C., comprising a hydrocracking step, optionally followed by a separation of the gases from the hydrocracked effluent, then a step for fractionation of said effluent, which separates at least one distillate and a residue, a portion of said residue being recycled to the hydrocracking step and another portion of the residue being purged, said fractionation step comprising a distillation in a column provided with plates, in which column:

-   -   said at least partially vaporized effluent supplies the column         over at least one supply plate,     -   said distillate is withdrawn from the level of a withdrawal         plate,     -   said residue is evacuated at an evacuation point,     -   and optionally, a stripping gas is injected at an injection         point located below the supply plate,         in which process     -   a portion of the stream present at the level of at least one         plate located between said supply plate and the plate for         withdrawing the heaviest distillate fraction is withdrawn from         the column, and     -   at least a portion of said withdrawn stream is recycled to the         column, directly or after optional liquid separation,     -   and optionally, at least a portion of said withdrawn stream is         recycled to the hydrocracking step directly or after optional         separation of the gases.

Advantageously, a portion of the stream present at the level of a plate located above the supply plate and close to said supply plate, preferably at the level of the plate which is closest to the supply plate, is withdrawn from the column.

Said withdrawn stream has a concentration of HPNA of less than 500 ppm by weight, preferably less than 350 ppm by weight and highly preferably less than 200 ppm by weight. It usually has a proportion of at least 70% by weight of unconverted hydrocarbons, preferably at least 80% by weight of unconverted hydrocarbons and highly preferably at least 90% by weight of unconverted hydrocarbons.

In accordance with one embodiment of the process in accordance with the invention, the entirety of said withdrawn stream is recycled directly to the column.

In accordance with one embodiment of the process in accordance with the invention:

-   -   a portion of said withdrawn stream is recycled directly (i.e.         without treatment of the withdrawn stream before recycling to         the column) to the column, for example as shown in FIG. 2 a,     -   the other portion of the withdrawn stream is recycled to the         hydrocracking step, directly or after optional separation of the         gases.

Advantageously, said stream (all or a portion) is recycled to the column below the supply plate and, when it exists, above the point for injection of the stripping gas. Highly preferably, in addition, it is recycled to the column at the level of the plate closest to said supply plate.

In accordance with another preferred embodiment of the process in accordance with the invention:

-   -   all or a portion, preferably all, of said withdrawn stream is         separated in an external stripping step using a stripping gas,         and     -   all or a portion, preferably all of the separated gaseous         effluent is recycled to the column above the plate from which         the stream has been withdrawn, and preferably to the level of a         plate close to the plate from which the stream has been         withdrawn,     -   preferably, in addition, the gaseous effluent is recycled to the         column to the level of the plate closest to the plate from which         the stream has been withdrawn,     -   preferably, in addition, all or a portion, preferably all of the         liquid effluent separated in said stripping step is recycled,         preferably directly to the hydrocracking step.

Furthermore, in a preferred disposition of this embodiment, the liquid fraction separated in the stripping step is not recycled to the fractionation column.

It should also be noted that preferably, in accordance with the invention, residue is not recycled to the fractionation step.

Preferably, the process operates in the presence of a stripping gas injected into the fractionation step. Preferably, it is steam, preferably at a pressure in the range 0.2 to 1.5 MPa.

The stripping gas injected into the external stripping step is preferably steam, preferably at a pressure in the range 0.2 to 1.5 MPa.

The hydrocracking step is carried out in conventional manner at a temperature of more than 200° C., a pressure of more than 1 MPa, a space velocity of 0.1 to 20 h⁻¹, and the H₂/hydrocarbons volume ratio is 80 to 5000 NL/L.

The invention also concerns a facility which is advantageously employed in order to carry out the process in accordance with the invention.

It comprises:

-   -   a hydrocracking section 2 provided with an inlet line 1 for the         feed and an inlet line 8 for hydrogen,     -   optionally followed by a zone 4 for separating effluent (line 3)         in order to separate a gaseous fraction (line 5),     -   followed by a fractionation section 12 comprising at least one         distillation column provided with plates, said column         comprising:         -   at least one line 11 for the inflow of at least partially             vaporized hydrocracked effluent onto at least one supply             plate,         -   at least one line 14 for withdrawing at least one distillate             from the level of a withdrawal plate,         -   at least one line 15 a for evacuating residue,     -   at least one line 23, 18 for recycling a portion of the residue         to the hydrocracking step,     -   and optionally comprising at least one line 19 for injecting a         stripping gas, the injection point being located below the         supply plate,         the facility further comprising:     -   at least one line 20 for withdrawing a portion of the stream         present at the level of at least one plate located between said         supply plate and the plate for withdrawing the heaviest         distillate fraction (i.e. above the supply plate),     -   and a line for recycling all or a portion of said withdrawn         stream to said column, directly (line 22 a) or after optional         liquid separation (line 22 b),     -   and optionally, a line for recycling all or a portion of said         withdrawn stream to the hydrocracking section, directly (line 17         a) or after an optional gas separation (line 17 b).

Preferably, the plate for withdrawing said stream from the line 20 is positioned at the level of a plate close to the supply plate. Highly preferably, the plate for withdrawing said stream from the line 20 is positioned at the level of the plate closest to the supply plate.

In one embodiment, the facility does not comprise treatment of the stream withdrawn before recycling to the column; it comprises a line 22 a for recycling the entirety of the withdrawn stream directly to the column (i.e. no treatment of the withdrawn stream before recycling to the column).

In one embodiment, the facility does not comprise a treatment of the stream withdrawn before recycling to the column, it comprises:

-   -   a line 22 a for recycling a portion of the withdrawn stream         directly to the column, and     -   a line 17 a for recycling a portion of the withdrawn stream         directly to the hydrocracking section 2,     -   advantageously, the line 22 a discharges at the level of a plate         located below the supply plate and, if it exists, above the         stripping gas injection point 19, and preferably to a plate         close to the supply plate,     -   preferably, the line 22 a discharges at the level of a lower         plate closest to the supply plate.

In another preferred embodiment, the facility in accordance with the invention comprises:

-   -   a stripper 25 external to the column, provided with an inlet         line 20 for said withdrawn stream, a stripping gas injection         line 26, an outlet line 22 b for the gaseous fraction, an outlet         line 17 b for the liquid fraction,     -   a line 22 b for recycling all or a portion, preferably all, of         said gaseous fraction to said column,     -   a line 17 b, 18 for recycling all or a portion, preferably all,         of said liquid fraction to the hydrocracking step,     -   a line 16 to purge a portion of the residue,     -   preferably, the recycling line 22 b discharges into the column         above the plate from which the stream has been withdrawn, and         preferably to the level of a plate close to the plate from which         the stream has been withdrawn, and preferably to the level of         the plate closest to the plate from which the stream has been         withdrawn.

In a preferred disposition of this embodiment, there is no line for recycling a liquid fraction separated in the stripping step towards the fractionation column.

Preferably, the facility in accordance with the invention does not comprise a line for recycling residue to the column.

In the text, feeds are defined by their T5 boiling point (as will be explained below). The conversion of the feed is defined with respect to the cut point of the residue. The unconverted fraction is termed residue. The converted fraction comprises the fractions sought by the refiner (objectives).

The invention will be better understood from the following description of the figures.

The purged portion refers to a portion which leaves the process.

FIG. 1 represents the prior art. FIGS. 2a and 2b represent the invention. The principle of the invention will be explained commencing from FIG. 2a . FIGS. 2a and 2b will be understood in combination with FIG. 1, and more precisely with the essential elements of FIG. 1 cited in the claims.

FIG. 1 presents a flowchart for a prior art hydrocracking process. To facilitate reading, the description of the conditions employed has been moved to a further part of the text below.

The feed (line 1) composed of hydrocarbons of oil origin and/or synthetic hydrocarbons with a mineral or biological source is mixed with hydrogen supplied via the lines 5 (recycle) and/or 6 (makeup hydrogen) via the compressor 7 and the line 8. The feed/hydrogen mixture thus formed is sent to the hydrocracking section 2. This section comprises one or more fixed bed or ebullated bed reactors.

When the hydrocracking section comprises one or more fixed bed reactors, each reactor may comprise one or more beds of catalyst carrying out hydrocracking of the hydrocarbons of the feed to form lighter hydrocarbons.

When the hydrocracking section comprises one or more ebullated bed reactors, a stream comprising liquid, solid and gas moves vertically through a reactor containing a bed of catalyst. The catalyst in the bed is maintained in a random motion in the liquid. The gross volume of the catalyst dispersed through the liquid is thus larger than the volume of catalyst when stopped. This technology has been widely described in the literature.

A mixture of liquid hydrocarbon and hydrogen is passed through the bed of particles of catalyst at a velocity such that the particles are caused to move in a random manner and thus become suspended in the liquid. Expansion of the catalytic bed in the liquid phase is controlled by the flow rate of recycle liquid in a manner such that in the equilibrium state, the major portion of catalyst does not go above a defined level in the reactor. The catalysts are in the form of extrudates or beads, preferably with a diameter in the range 0.8 mm to 6.5 mm in diameter.

In an ebullated bed process, large quantities of hydrogen gas and light hydrocarbon vapours rise through the reaction zone then in a zone which is free of catalyst. A portion of the liquid from the catalytic zone is recycled to the bottom of the reactor after separating a gaseous fraction and a portion is withdrawn from the reactor as product, usually at the top portion of the reactor.

The reactors used in an ebullated bed process are generally designed with a central vertical recycling conduit which acts as a flow tube for recycling liquid from the catalyst-free zone located above the ebullated bed of catalyst, via a recycling pump which can be used to recycle the liquid in the catalytic zone. Recycling the liquid means that both a uniform temperature can be maintained in the reactor and that the bed of catalyst can be kept in suspension.

The hydrocracking section may be preceded by or include one or more beds of hydrotreatment catalyst(s).

The effluent from the hydrocracking section 2 is sent via line 3 to a separation zone 4 in order to recover a gaseous fraction 5 on the one hand, along with a liquid fraction 9. The gaseous fraction 5 contains excess hydrogen which has not reacted in the reaction section 2. It is generally combined with fresh hydrogen arriving via the line 6 in order to be recycled as indicated below.

The liquid fraction 9 is reheated by any means 10, for example a furnace which could be associated with an exchanger (not shown), in order to at least partially vaporize it before supplying the fractionation section 12 via the line 11.

The fractionation section 12 comprises one or more distillation columns equipped with plates and contact means in order to separate various upgradeable cuts (distillates) which are withdrawn by means of the lines 13 and 14, plus other optional side streams. These cuts have boiling point ranges situated, for example, in the gasoline, kerosene and gas oil ranges.

A heavier unconverted fraction (residue) is recovered from the bottom of the column (line 15 a).

Stripping gas may be injected via the line 19. This line is located between the plate for supplying hydrocracked effluent (line 11) and the residue evacuation point (line 15 a).

A portion of the residue may be purged via the line 16, with another portion recycled to the hydrocracking section via the lines 23 and 18 and another portion recycled to the fractionation section (line 15 b).

In accordance with FIG. 1, a portion (line 15 b) of the residue from the line 15 a is mixed with the supply (line 9) upstream of the furnace 10 of the fractionation section and recycled as a mixture towards the fractionation section (line 11).

The purge 16 can in particular be used to eliminate at least a portion of the HPNA compounds which could accumulate in the recycle loop without this purge.

The zone E outlined in FIG. 1 defines the portion modified by the subject matter of the present invention.

FIGS. 2a and 2b present the invention.

The elements described above will not be described again here. It will be noted that the line 15 b (recycle of residue to the fractionation column) is preferably dispensed with in the invention.

The fractionation section 12 comprises a single fractionation column. However, the invention could be implemented with several fractionation columns and at least one column would then comprise a zone E in accordance with the invention.

In accordance with FIG. 2a , the liquid fraction 11 which has previously been at least partially vaporized is supplied to the fractionation section 12.

Preferably, a stripping gas is injected into the column (line 19). Advantageously, it is steam, preferably low pressure steam, preferably at a pressure in the range 0.2 to 1.5 MPa (0.1 MPa=1 bar or 1 barg). The injection point is located below the supply plate and above the residue evacuation point. It is preferably close to the point for evacuation of residue from the bottom of the column.

FIG. 2a differs from FIG. 1 primarily in that a side stream is added (line 20) at one of the plates of the column. It is possible to position one or more side streams at the level of the column. Thus, a portion of the stream present at the level of at least one plate located between the plate for supplying effluent and the plate (line 14) for withdrawing the heaviest distillate fraction is withdrawn.

This withdrawal (line 20) is preferably close to the supply plate. Preferably, a portion of the stream present at the level of the plate closest to the supply plate is withdrawn from the column.

All or a portion of said withdrawn stream is recycled directly to the column (line 22 a).

FIG. 2b (described below) describes another embodiment in which recycling to the column is carried out after separation of the liquid.

FIG. 2a presents the case in which a portion of the side stream (line 20) is recycled to the column (line 22 a), the other portion of the side stream (line 17 a) being recycled (line 18) to the hydrocracking step, preferably as a mixture with the portion of the residue recycled (line 23) to the hydrocracking step.

The side stream (line 20) is positioned in a manner such that the withdrawn stream has a low concentration of HPNA of less than 500 ppm by weight, preferably less than 350 ppm by weight and highly preferably less than 200 ppm by weight, and most often, a large proportion of unconverted hydrocarbons in the hydrocracking section of at least 70% by weight of unconverted hydrocarbons, preferably at least 80% by weight of unconverted hydrocarbons and highly preferably at least 90% by weight of unconverted hydrocarbons.

In order to satisfy these criteria, the side stream (line 20) is preferably positioned above the supply plate, and preferably at the level of the plate closest to the supply plate.

In this embodiment (such as FIG. 2a ), the withdrawn stream is re-injected below the supply plate and, when it exists, above the point for injecting stripping gas, and preferably to the level of the plate closest to the supply plate.

The reference numerals in FIGS. 1 and 2 a will not be described again in the description of FIG. 2b . FIG. 2b differs from FIG. 2a in respect of the treatment and recycling of the withdrawn stream.

In accordance with FIG. 2b , all or a portion of said withdrawn stream is recycled to the column after separating the liquid.

Preferably, the withdrawn stream (line 20) is stripped in an external stripping step (stripper 25) by a stripping gas (supplied via the line 26). All or a portion of the separated gaseous effluent is recycled to the column; in accordance with FIG. 2b , all of the gaseous effluent is recycled (22 b).

The side stream (line 20) is positioned in the same manner as in FIG. 2 a.

Preferably, the gaseous effluent is recycled to the column above the plate from which the stream has been withdrawn. In addition, better performances are obtained when the gaseous effluent is recycled to the column to the plate closest to the plate from which the stream has been withdrawn.

All or a portion of the liquid effluent (line 17 b) is recycled, usually directly, to the hydrocracking step. In accordance with FIG. 2b , all of the liquid effluent is mixed with the recycled residue portion (line 23) and the mixture is recycled (line 18) to the hydrocracking step.

Said lateral stripper 25 functions with injection of a stripping gas (line 26). This gas is preferably steam, preferably low pressure steam, preferably at a pressure in the range 0.2 to 1.5 MPa.

As will be demonstrated in the examples below, the embodiment of FIG. 2b results in better performances than the embodiment of FIG. 2 a.

Description of the Conditions for the Hydrocracking, 2, and Separation Steps

This description refers to conventional implementational conditions which can be applied both to FIG. 1 (prior art) and to the invention (FIGS. 2a and 2b ).

Feeds:

A wide variety of feeds may be treated in hydrocracking processes. In general, they contain at least 10% by volume, generally at least 20% by volume and often at least 80% by volume of compounds boiling above 340° C.

The feed may, for example, be LCOs (light cycle oil—light gas oils obtained from a catalytic cracking unit), atmospheric distillates, vacuum distillates, for example gas oils obtained from straight run distillation of crude or from conversion units such as FCC, coking or visbreaking, as well as feeds originating from units for the extraction of aromatics from lubricating oil bases or obtained from solvent dewaxing of lubricating base oils, or in fact from distillates originating from processes for fixed bed or ebullated bed hydroconversion or desulphurization of AR (atmospheric residues) and/or VR (vacuum residues) and/or deasphalted oils, or the feed may in fact be a deasphalted oil, effluents from a Fischer-Tropsch unit or in fact any mixture of the feeds cited above. The above list is not limiting.

In general, the feeds have a T5 boiling point of more than 150° C. (i.e. 95% of the compounds present in the feed have a boiling point of more than 150° C.). In the case of gas oil, the T5 point is generally approximately 150° C. In the case of VGO, the T5 is generally more than 340° C., or even more than 370° C. The feeds which may be used thus fall within a wide range of boiling points. This range generally extends from gas oil to VGO, encompassing all possible mixtures with other feeds, for example LCO.

The nitrogen content of the feeds treated in the hydrocracking processes is usually more than 500 ppm by weight, generally in the range 500 to 10000 ppm by weight, more generally in the range 700 to 4500 ppm by weight and still more generally in the range 800 to 4500 ppm by weight.

The sulphur content in the feeds treated in the hydrocracking processes is usually in the range 0.01% to 5% by weight, generally in the range 0.2% to 4% by weight and yet more generally in the range 0.5% to 3% by weight. The feed may optionally contain metals. The cumulative nickel and vanadium content in the feeds treated in hydrocracking processes is preferably less than 10 ppm by weight, preferably less than 5 ppm by weight and yet more preferably less than 2 ppm by weight. The asphaltenes content is generally less than 3000 ppm by weight, preferably less than 1000 ppm by weight, and yet more preferably less than 300 ppm by weight.

Guard Beds

In the case in which the feed contains compounds of the resins and/or asphaltenes type, it is advantageous to initially pass the feed over a bed of catalyst or adsorbent which differs from the hydrocracking or hydrotreatment catalyst. The catalysts or guard beds used are in the shape of spheres or extrudates. Any other shape may be used. Particular possible shapes which may be used are included in the following non-limiting list: hollow cylinders, hollow rings, Raschig rings, toothed hollow cylinders, crenelated hollow cylinders, wheels known as pentarings, multiple-holed cylinders, etc. These catalysts may have been impregnated with a phase which may or may not be active. Preferably, the catalysts are impregnated with a hydrodehydrogenating phase. Highly preferably, the CoMo or NiMo phase is used. These catalysts may have a macroporosity.

Operating Conditions:

The operating conditions such as temperature, pressure, hydrogen recycle ratio, or hourly space velocity may vary widely as a function of the nature of the feed, the quality of the desired products and the facilities available to the refiner. The hydrocracking/hydroconversion catalyst or hydrotreatment catalyst is generally brought into contact with the feeds described above in the presence of hydrogen, at a temperature of more than 200° C., often in the range 250° C. to 480° C., advantageously in the range 320° C. to 450° C., preferably in the range 330° C. to 435° C., at a pressure of more than 1 MPa, often in the range 2 to 25 MPa, preferably in the range 3 to 20 MPa, the space velocity being in the range 0.1 to 20 h⁻¹, preferably in the range 0.1 to 6 h⁻¹, and more preferably in the range 0.2 to 3 h⁻¹, and the quantity of hydrogen introduced being such that the volume ratio in litres of hydrogen/litres of hydrocarbon is in the range 80 to 5000 NL/L, usually in the range 100 to 3000 NL/L.

These operating conditions used in the hydrocracking processes can generally be used to obtain conversions per pass into converted products (i.e. with boiling points below the residue cut point) of more than 15%, and more preferably in the range 20% to 95%.

The Principal Aims:

The invention may be used in all hydrocrackers, namely:

-   -   the maxi-naphtha hydrocracker with a residue cut point which is         generally between 150° C. and 190° C., preferably between         160° C. and 190° C., and usually 170° C.-180° C.,     -   the maxi-kerosene hydrocracker with a residue cut point which is         generally between 240° C. and 290° C., and usually 260° C.-280°         C.,     -   the maxi-gas oil hydrocracker with a residue cut point which is         generally between 340° C. and 385° C., and usually 360° C.-380°         C.

EMBODIMENTS

The hydrocracking/hydroconversion processes using the catalysts in accordance with the invention cover the ranges of pressure and conversion from mild hydrocracking to high pressure hydrocracking.

The term “mild hydrocracking” means hydrocracking resulting in moderate conversions, generally below 40%, and operating at low pressures, generally between 2 MPa and 9 MPa. The hydrocracking catalyst may be used alone, in a single or in more fixed bed catalytic beds, in one or more reactors, in a “once-through” hydrocracking layout, with or without liquid recycling of the unconverted fraction, optionally in association with a hydrorefining catalyst located upstream of the hydrocracking catalyst.

The hydrocracking may be operated at high pressure (at least 10 MPa).

In a first variation, the hydrocracking may be operated in accordance with a hydrocracking layout which is known as a “two-step” layout, with intermediate separation between the two reaction zones; in a given step, the hydrocracking catalyst may be used in one or in both reactors associated or otherwise with a hydrorefining catalyst located upstream of the hydrocracking catalyst.

In a second variation, what is known as “once-through” hydrocracking may be carried out. This variation generally initially comprises intense hydrorefining which is intended to carry out intense hydrodenitrogenation and hydrodesulphurization of the feed before it is sent to the hydrocracking catalyst proper, in particular in the case in which it comprises a zeolite. This intense hydrorefining of the feed brings about only a limited conversion of this feed into lighter fractions. The conversion, which is still insufficient, must therefore be supplemented on the more active hydrocracking catalyst.

The hydrocracking section may contain one or more beds of identical or different catalysts. When the preferred products are middle distillates, basic amorphous solids are used, for example alumina or silica-aluminas or basic zeolites, optionally supplemented with at least one hydrogenating metal from group VIII and preferably also supplemented with at least one metal from group VIB. These basic zeolites are composed of silica, alumina and one or more exchangeable cations such as sodium, magnesium, calcium or rare earths.

When gasoline is the major desired product, the catalyst is generally composed of a crystalline zeolite onto which small quantities of a metal from group VIII are deposited, and also, more preferably, a metal from group VIB.

The zeolites which may be used are natural or synthetic and may, for example, be selected from X, Y or L zeolites, faujasite, mordenite, erionite or chabasite.

Hydrocracking may be carried out in just one or in more ebullated bed reactors, with or without a liquid recycle of the unconverted fraction, optionally in association with a hydrorefining catalyst located in a fixed bed or ebullated bed reactor upstream of the hydrocracking catalyst. The ebullated bed is operated with withdrawal of spent catalyst and the daily addition of fresh catalyst in order to keep the catalyst activity stable.

Liquid/Gas Separation (4):

The separator 4 separates the liquid and gas present in the effluent leaving the hydrocracking unit. Any type of separator that can carry out this separation may be used, for example a flash drum, a stripper, or even a simple distillation column.

Fractionation (12):

The fractionation section is generally constituted by one or more columns comprising a plurality of plates and/or internal packing which may preferably be operated in counter-current mode. These columns are usually steam stripped and include a reboiler in order to facilitate vaporization. It can be used to separate hydrogen sulphide (H₂S) and light components (methane, ethane, propane, butane etc) from the effluents, as well as the hydrocarbon cuts with boiling points in the gasoline, kerosene and gas oil ranges along with a heavy fraction recovered from the bottom of the column, all or a portion of which may be recycled to the hydrocracking section.

EXAMPLES Example 1: Prior Art

This example is based on the configuration of FIG. 1. Two samples from an operating industrial unit based on the configuration of FIG. 1 were analysed. The properties are recorded in Table 1 below.

It should be noted that because of the configuration, the streams 15 a, 16, 18 and 23 had exactly the same properties.

The fractionation of stream 11 in the column 12 was computer simulated using the PRO/II version 8.3.3 software marketed by SimSci. The physical and analytical properties of the resulting streams were simulated and compared with the physical and analytical properties of actual samples.

The operating conditions for the column used for the simulation are recorded in Table 2 below.

TABLE 1 Properties of the streams of the layout of FIG. 1 Streams from FIG. 1 Stream number Configuration 11 15a 18 16 Yield % by wt 100 42 39.5 2.5 Quantity of gas % by wt 64.0 10.9 10.9 10.9 oil in stream Density 0.805 0.828 0.828 0.828 HPNA Coronene ppm by wt 209 497 497 497 Dibenzo(e,ghi)per- ppm by wt 33 78 78 78 ylene Naphtho[8,2,1 abc] ppm by wt 81 192 192 192 coronene Ovalene ppm by wt 57 135 135 135 Total HPNA ppm by wt 378 902 902 902 TBP, % by wt Initial boiling point ° C. 128 200 200 200 10% ° C. 200 368 368 368 50% ° C. 326 402 402 402 90% ° C. 440 477 477 477 Final boiling point ° C. 524 524 524 524 1: Specific gravity SG = ρ_(sample) at 20° C./ρ_(H20) at 4° C., where ρ is the density expressed in g/cm³

Starting from the properties of the stream 11 entering the fractionation column (see Table 1), the PRO/II simulation was able to establish the properties of the stream 15 leaving the fractionation column; in particular, the HPNA distribution could be modelled.

TABLE 2 Operating conditions for the column Operating conditions for fractionation FIG. 1 Pressure, top of column Barg 1.0 Pressure, bottom of column Barg 1.5 Temperature, inlet feed ° C. 377 Number of theoretical plates 34 Flow rate of stripping steam kg of steam/tonne of feed 17

Based on these results, the configurations of the invention were simulated. The results are disclosed below for each configuration.

Example 2: Configuration 2 a

Table 3 below provides the characteristics of the streams 11, 16 and 18 in the configuration 2 a obtained from the PRO/II simulation. The operating conditions used for the simulation are recorded in Table 4.

TABLE 3 Properties of the streams of the layout of FIG. 2a Streams from FIG. 2a Stream number 11 18 16 Configuration inlet liquid recycle purge Yield 100 39.5 2.5 Quantity of gas oil in stream 64.0 14.8 5.1 Density 0.805 0.8275 0.832 HPNA Coronene 209 422 2192 Dibenzo(e,ghi)perylene 33 96 314 Naphtho [8,2,1 abc] coronene 81 114 895 Ovalene 57 70 640 Total HPNA 378 702 4041 TBP, % by wt Initial boiling point 128 79 251 10% 200 362 389 50% 326 401 425 90% 440 476 505 Final boiling point 524 524 524 1: Specific gravity SG = ρ_(sample) at 20° C./ρ_(H20) at 4° C., where ρ is the density expressed in g/cm³

TABLE 4 Operating conditions for the column Operating conditions for fractionation FIG. 2a Pressure, top of column Barg 1.0 Pressure, bottom of column Barg 1.5 Temperature, inlet feed ° C. 377 Number of theoretical plates 34 Flow rate of stripping steam kg of steam/tonne of feed 17

Compared with the configuration of FIG. 1, the configuration 2 a can be used to maximize the quantity of HPNA (4041 ppm by weight compared with 902 ppm by weight in configuration 1) in the unconverted fraction (residue) which was purged via the line 16. At the same time, the quantity of HPNA was minimized in the stream which returns to the reaction section via the line 18: 702 ppm by weight (by wt) compared with 902 ppm by weight in configuration 1, which reduced the quantity of HPNA by 22.2%.

In addition, the proportion of heavy HPNA (naphtho [8,2,1 abc] coronene+ovalene) compared with the total quantity of HPNA in the stream 18 returning to the reaction section was much lower for the configuration 2 a (26.3%) than for the configuration 1 (36.3%). This indicates that not only was there less total HPNA in the stream returning to the reaction section via the line 18, but also, the proportion of the most refractory and poisonous heavy HPNA (naphtho [8,2,1 abc] coronene+ovalene) was lower.

Example 3: Configuration 2 b

Table 5 below provides the characteristics obtained from the PRO/II simulation for the streams 11, 16 and 18 in the configuration 2 b. The operating conditions used for the simulation are recorded in Table 6.

TABLE 5 Properties of the streams of the layout of FIG. 2b Streams from FIG. 2b Stream number 11 18 16 Configuration inlet liquid recycle purge Yield 100 39.5 2.5 Quantity of gas oil in stream 64.0 6.6 5.7 Density 0.805 0.8291 0.8313 HPNA Coronene 209 388 2500 Dibenzo(e,ghi) perylene 33 78 375 Naphtho [8,2,1 abc] coronene 81 122 994 Ovalene 57 80 704 Total HPNA 378 668 4573 TBP, % by wt Initial boiling point 128 217 210 10% 200 384 380 50% 326 401 421 90% 440 476 504 Final boiling point 524 524 524 1: Specific gravity SG = ρ_(sample) at 20° C./ρ_(H20) at 4° C., where ρ is the density expressed in g/cm³

TABLE 6 Operating conditions for the column FIG. 2b Operating conditions for fractionation Pressure, top of column Barg 1.0 Pressure, bottom of column Barg 1.5 Temperature, inlet feed ° C. 377 Number of theoretical plates 34 Flow rate of stripping steam kg of steam/tonne of feed 17 operating conditions for side stripper Pressure, top of column Barg 1.4 Pressure, bottom of column Barg 1.5 Number of theoretical plates 6 Flow rate of stripping steam kg of steam/t of feed 28

Compared with FIG. 1, the configuration 2 b can be used to maximize the quantity of HPNA: 4573 ppm by weight compared with 902 ppm by weight for configuration 1 in the unconverted fraction (residue) which was purged via the line 16. At the same time, the quantity of HPNA was minimized in the stream leaving the reaction section via the line 18: 668 ppm by weight compared with 902 ppm by weight for configuration 1, which reduced the quantity of HPNA by 25.9%.

In addition, the proportion of the most refractory and poisonous heavy HPNA (naphtho [8,2,1 abc] coronene+ovalene) compared with the total quantity of HPNA in the stream 18 returning to the reaction section was much lower for configuration 2 b (30.3%) than for configuration 1 (36.3%). This indicates that not only was there less total HPNA in the stream returning to the reaction section via the line 18, but also that the proportion of heavy HPNA (naphtho [8,2,1 abc] coronene+ovalene) was lower.

This configuration could also minimize the quantity of gas oil sent to the reaction section via the line 18 because the quantity of gas oil included in the stream which was sent to the reaction section via the line 18 was only 6.6% by weight compared with 10.9% by weight in configuration 1. 

1. A process for hydrocracking an oil feed comprising at least 10% by volume of compounds boiling above 340° C., comprising a hydrocracking step, optionally followed by a separation of the gases from the hydrocracked effluent, then a step for fractionation of said effluent, which separates at least one distillate and a residue, a portion of said residue being recycled to the hydrocracking step and another portion of the residue being purged, said fractionation step comprising a distillation in a column provided with plates, in which column: said at least partially vaporized effluent supplies the column over at least one supply plate, said distillate is withdrawn from the level of a withdrawal plate, said residue is evacuated at an evacuation point, and optionally, a stripping gas is injected at an injection point located below the supply plate, in which process a portion of the stream present at the level of at least one plate located between the supply plate and the plate for withdrawing the heaviest distillate fraction is withdrawn from the column, and at least a portion of said withdrawn stream is recycled to the column, directly or after optional liquid separation, and optionally, at least a portion of said withdrawn stream is recycled to the hydrocracking step directly or after optional separation of the gases.
 2. The process as claimed in claim 1, in which a portion of the stream present at the level of a plate located above the supply plate and close to said supply plate, preferably at the level of the plate which is closest to the supply plate, is withdrawn from the column.
 3. The process as claimed in claim 1, in which said withdrawn stream has a concentration of HPNA of less than 500 ppm by weight, preferably less than 350 ppm by weight.
 4. The process as claimed in claim 1, in which said withdrawn stream has a proportion of at least 70% by weight of unconverted hydrocarbons, preferably at least 80% by weight of unconverted hydrocarbons.
 5. The process as claimed in claim 1, in which the entirety of said withdrawn stream is recycled directly to the column.
 6. The process as claimed in claim 1, in which a portion of said withdrawn stream is recycled directly to the column, the other portion of the withdrawn stream being recycled to the hydrocracking step, directly or after optional separation of the gases.
 7. The process as claimed in claim 1, in which said withdrawn stream is recycled to the column above the supply plate and, when it exists, above the point for injection of the stripping gas.
 8. The process as claimed in claim 7, in which said withdrawn stream is recycled to the column at the level of a plate close to said supply plate, and preferably to the level of the plate closest to said supply plate.
 9. The process as claimed in claim 1, in which all or a portion, preferably all, of said withdrawn stream is stripped in an external stripping step using a stripping gas, and all or a portion, preferably all of the separated gaseous effluent is recycled to the column above the plate from which the stream has been withdrawn.
 10. The process as claimed in claim 9, in which the gaseous effluent is recycled to the column at the level of the plate closest to the plate from which the stream has been withdrawn
 11. The process as claimed in claim 9, in which all or a portion, preferably all of the liquid effluent separated in said stripping step is recycled directly to the hydrocracking step.
 12. The process as claimed in claim 1, in which a stripping gas is injected into the fractionation step.
 13. The process as claimed in claim 1, in which the stripping gas injected into the external stripping step and, if it is present, into the fractionation step is steam, preferably at a pressure of 0.2-1.5 MPa.
 14. The process as claimed in claim 1, which does not comprise recycling the residue to said fractionation step.
 15. A facility comprising: a hydrocracking section (2) provided with an inlet line (1) for the feed and an inlet line (8) for hydrogen, optionally followed by a zone (4) for separating effluent (line 3) in order to separate a gaseous fraction (line 5), followed by a fractionation section (12) comprising at least one distillation column provided with plates, said column comprising: at least one line (11) for the inflow of at least partially vaporized hydrocracked effluent onto at least one supply plate, at least one line (14) for withdrawing at least one distillate from the level of a withdrawal plate, at least one line (15 a) for evacuating residue, at least one line (23, 18) for recycling a portion of the residue to the hydrocracking step, and optionally comprising at least one line (19) for injecting a stripping gas, the injection point being located below the supply plate, the facility further comprising: at least one line (20) for withdrawing a portion of the stream present at the level of at least one plate located between said supply plate and the plate for withdrawing the heaviest distillate fraction, and a line for recycling all or a portion of said withdrawn stream to said column, directly (line 22 a) or after optional liquid separation (line 22 b), and optionally, a line for recycling all or a portion of said withdrawn stream to the hydrocracking section, directly (line 17 a) or after an optional gas separation (line 17 b).
 16. The facility as claimed in claim 15, in which the plate for withdrawing said stream from the line (20) is positioned at the level of a plate close to the supply plate, and preferably at the level of the plate closest to the supply plate.
 17. The facility as claimed in claim 15, which does not comprise treatment of the stream withdrawn before recycling to the column, said facility comprising a line (22 a) for recycling the entirety of the withdrawn stream directly to the column.
 18. The facility as claimed in claim 15, which does not comprise a treatment of the stream withdrawn before recycling to the column, said facility comprising: a line (22 a) for recycling a portion of the withdrawn stream directly to the column, and a line (17 a) for recycling a portion of the withdrawn stream directly to the hydrocracking section (2), advantageously, the line (22 a) discharges at the level of a plate located below the supply plate and, if it exists, above the stripping gas injection point, preferably, in addition, the line (22 a) discharges at the level of the lower plate closest to the supply plate.
 19. The facility as claimed in claim 15, comprising: a stripper (25) external to the column, provided with an inlet line (20) for said withdrawn stream, a stripping gas injection line (26), an outlet line (22 b) for the gaseous fraction, an outlet line (17 b) for the liquid fraction, a line (22 b) for recycling all or a portion, preferably all, of said gaseous fraction to said column, preferably, the recycling line (22 b) discharges into the column above the plate from which the stream has been withdrawn, and preferably from the level of the plate closest to the plate from which the stream has been withdrawn, a line (17 b, 18) for recycling all or a portion, preferably all, of said liquid fraction to the hydrocracking step, a line (16) to purge a portion of the residue, preferably, there is no line for recycling a liquid fraction separated in the stripping step towards the fractionation column.
 20. The facility as claimed in claim 15, which does not comprise a line for recycling residue to the column. 